Method Statement For GRE Piping Tanga

Document Number:
TZ-TAN-94-BBJ1-200388
Method Statement - Field GRE Piping Installation Revision: 00 Step: IFR
Rev. Date:
Doc. Type: PRC Discipline: PIP Phase: CS Class: 2 Page 1 of 28
CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA
EACOP Project
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Method Statement - Field GRE Piping installation
Rajib Banerjii Mehmet Yilmaz C. Eris / F.

Springuel
Rev. Step Date Revision Description Issued by Reviewed by Approved by
This document is the property of COMPANY and shall not be disclosed to third parties or reproduced without permission of the owner.
Document Number:
TZ-TAN-94-BBJ1-200388
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HOLD LOG
HOLD No. Description of Holds
Document Number:
TZ-TAN-94-BBJ1-200388
Rev. Date:
COMMENT RESPONSE SHEET
Document Number:
TZ-TAN-94-BBJ1-200388
Rev. Date:
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status

Risk Management Plan
HESE Plan
HIRA
Emergency Response Plan
Quality Management Plan
Piping Material Class Specification
Method Statement -Field MEP works Material Traceability and
ETJ-WC-DE-MS-GEN-ME-0002
Control
Method Statement - Field Welding Traceability and Control for
ETJ-WC-DE-MS-GEN-ME-0008
Piping works
ETJ-WC-DE-MS-GEN-ME-0005 Method Statement - Field PWHT Works
ETJ-WC-DE-MS-GEN-ME-0006 Method Statement - Field Pipe Welding Repair Procedure
TZ-TAN-94-BBJ1-200257 Method Statement - Flange Management – PVV
Document Number:
TZ-TAN-94-BBJ1-200388
Rev. Date:
TABLE OF CONTENTS
1 INTRODUCTION............................................................................................................
1.1 Project Description..................................................................................................................7
1.2 Document Purpose...................................................................................................................8
1.3 Acronyms, Abbreviations and Definitions................................................................................8
1.4 Requirements & Standards......................................................................................................9
1.5 Permits & Tolerances..............................................................................................................9
2 THE WORK.....................................................................................................................
2.1 Work Location........................................................................................................................9
2.2 Scope of Work.......................................................................................................................10
2.3 Roles and Responsibilities......................................................................................................11
2.4 a) Project Manager:..............................................................................................................11
2.5 b) HSE Officer:.....................................................................................................................11
2.6 c) Piping Engineer..............................................................................................................11
2.7 d) QA/QC Inspector...........................................................................................................11
2.8 e) Piping Supervisor...........................................................................................................11
2.9 Planned Start Date and Duration...........................................................................................11
3 SEQUENCES OF WORKS.............................................................................................
3.1 Approved Construction drawings..........................................................................................12
3.2 Traceability of Pipe Spool and its components: (Material receiving and control)...................12
3.3 Dimensional Check:...............................................................................................................12
3.4 Preparations:.........................................................................................................................13
3.5 Cutting & Bevelling for Field Joints.......................................................................................13
3.6 Fit – Up.................................................................................................................................13
3.7 Lamination of the adhesive bondedJoint................................................................................14
3.8 Application of heat blanket....................................................................................................15
3.9 GRE flange joint..................................................................................................................16
3.10 Pipe supports installation.......................................................................................................16
3.11 Pipe cleaning and preservation..............................................................................................17
3.12 Hydro test..............................................................................................................................17
3.13 Valves and Equipment installation.........................................................................................18
Document Number:
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Rev. Date:
3.14 HANDLING AND STORAGE...............................................................................................18

3.15 Materials control...................................................................................................................18
3.16 Handling..............................................................................................................................18
3.17 Storage of GRE Pipe...........................................................................................................19
4 HEALTH, SAFETY AND ENVIRONMENT...................................................................

4.1 Health and Safety..................................................................................................................20
4.2 Tasks Daily Briefings.............................................................................................................20
5 EQUIPMENT AND MATERIAL....................................................................................

5.1 Equipment.............................................................................................................................21
5.1.1 Construction Equipment.................................................................................................21
6 PERSONNEL.................................................................................................................
6.1 Personnel Protective Equipment (PPE)..................................................................................21
6.2 MAN POWER.......................................................................................................................22
6.2.1 Supervision Staff...........................................................................................................22
6.2.2 Execution Staff..............................................................................................................22
6.2.3 Man power....................................................................................................................22
6.3 DECRIPTION OF THE WORK............................................................................................22
6.4 Pipe Installation in the Shallow Section..................................................................................22
6.4.1 Straight pipes installation in the shallow section...............................................................22
6.5 Expansion Loop in shallow section.........................................................................................23
6.6 Pipe Installation in the Deep Section......................................................................................24
Document Number:
TZ-TAN-94-BBJ1-200388
Rev. Date:
1 INTRODUCTION
1.1 Project Description
The EACOP Project is part of the Lake Albert Development, located in Uganda. The project
compromises a 1,443km cross-country pipeline development to enable the transport of heavy and waxy
crude oil reserves located in the Albertine Graben in Uganda, to a terminal in Tanga on the East Coast of
Tanzania.
Once constructed and operational, the Crude oil will be loaded on vessels via a facility located in the near
shore environment of the Indian Ocean. The Facility will be located approximately 2 km offshore from
the Marine Storage Terminal site located on the Chongoleani peninsula in front of Tanga Port in
Tanzania.
Figure 1 : Tanga & Chongoleani Satellite view (left) and Jetty location (right)
This Facility is a jetty, which consists of an access trestle formed of steel pipe racks mounted on steel
piles and at the jetty head a loading platform (LOF) consisting of a concrete deck placed on steel piles.
The top-side of the access trestle is made of a 3m wide road with passing bays, and technical platforms,
the main one being the EITS platform which provides control systems for the operational phase. The pipe
racks are fitted with a 30 inch pipe exporting the crude oil, Fire Water and Foam pipes and have several
expansion loops.
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The LOF will be equipped of three loading arms, specific piping, fire ‐fighting systems and other services.
On each side of this platform there will be independent structures above water, called dolphins, connected
by walkways.
1.2 Document Purpose
The purpose of this method is to implement responsibility for the installation of the GRE piping
systems under EACOP Project Tanga Site. It serves to define the methods and processes to be
adopted to ensure all GRE piping systems are installed in accordance with the appropriate project
specifications.
1.3 Acronyms, Abbreviations and Definitions

The following acronyms, abbreviations and definitions apply to this document:
TERM DEFINITION
BBN BESIX BALLAST NEDAM
WCL WELD-CON LIMITED
SCS STANDARD CONSTRUCTION SPECIFICATION
GRE GLASS-FIBER REINFORCED EPOXY
RA RISK ASSESSMENT
QC QUALITY CONTROLER
COMPANY EACOP LIMITED
CONTRACTOR BESIX BALLAST NEDAM LIMITED
EACOP EAST AFRICAN CRUDE OIL PIPELINE
EHT ELECTRICAL HEAT TRACING
ELECTRICAL, INSTRUMENTATION CONTROLS AND
EITS
TELECOM SYSTEMS
HEALTH, SAFETY, SECURITY, SOCIAL AND
H3SE
ENVIRONMENT
HSE HEALTH, SAFETY AND ENVIRONMENT
ITP INSPECTION AND TEST PLAN
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TERM DEFINITION
LOF LOAD OUT FACILITY
MS METHOD STATEMENT
MST MARINE STORAGE TERMINAL
1.4 Requirements & Standards

1. TZ-TAN-93-BBJ1-100151 Risk Management Plan
2. TZ-TAN-93-BBJ1-110001 H3S Plan
3. TZ-TAN-93-BBJ1-110017 Hazard Identification and Risk Assessment (HIRA)
Procedure
4. TZ-TAN-93-BBJ1-110006 Emergency Response Plan
5. TZ-TAN-93-BBJ1-030001 Quality Management Plan
6. UT-MID-60-WPR2-200002 Piping Material Class Specification
7. TZ-TAN-94-BBJ1-200249 Method Statement – Piping and Pipe Support
8. ASME B31.3 = Process Piping
9. ASME B16.5 Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch
Standard
1.5 Permits & Tolerances
Tolerances shall be as per dimensional tolerances and allowable misalignments applied to
fabricated GRE piping systems in addition to those specified within ASME B31.3 and PFI ES-3.
The below tolerance shall be followed during fabrication. Where A = ± 3.0mm from the indicated
dimensions on the GRE piping isometrics up to and including pipe diameters of NPS 10. For
larger diameters up to and including NPS 36 then A = ± 4.8mm
2 THE WORK
2.1 Work Location

Trestle Sections & EITS Platform & LOF and Dolphin Sections
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2.2 Scope of Work
Figure 2: Flow Chart for GRE pipe installation.

1) GRE Pipe Handling Dimensional check
2) Joint preparation before fit-up
3) Alignment of Pipe with support inside Trussell.
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4) GRE Pipe Fit up.

5) Lamination of Fit up Joint.
6) Pipe support installation
7) Valve installation
2.3 Roles and Responsibilities

2.4 a) Project Manager:
Will be wholly and solely responsible for the above scope of work and he will be representing
WCL for the entire Project duration.
2.5 b) HSE Officer:

Has the overall responsibility regarding development, implementation and monitoring of HSE
program capable of achieving lowest exposure to hazards and accidents on site.
Design department of Project Control Team. The design department of the project control team
shall be responsible for the composition and distribution of Isometric piping drawings, As-Built
drawings and the compilation of piping test package
2.6 c) Piping Engineer

Will be responsible for alignment the above task with the respective Supervisor and site frontline
workforce with guidance from Project Manager and coordination with Client & Consultant
concern persons to achieve the Project Target.
2.7 d) QA/QC Inspector

Will be responsible for inspection of all execution starting from Material traceability, dimension
check, Fit up, PWHT and final NDT with coordination with Project Manager, Piping Engineer and
Supervisor. During work the main responsibility will be monitoring the fitter for better fitting and
target for minimum tolerance or defect.
2.8 e) Piping Supervisor

Will be responsible for streamlining the Work force deployment on job and coordinating with
Piping Engineer for executing the Piping Work.
Document Number:
TZ-TAN-94-BBJ1-200388
Rev. Date:
2.9 Planned Start Date and Duration

The planned start date is 30th June 2024 and Duration is 13 months
3 SEQUENCES OF WORKS
3.1 Approved Construction drawings
AFC drawings and Isometrics are to be used for fabrication and installation. Reference is to be
made to these drawings for identification, arrangement, and specification of the pipe and its
components.
3.2 Traceability of Pipe Spool and its components: (Material receiving and control)
To have controlled storage and issuance of GRE piping material. A control list is to be used to
indicate the material in stock and the issued material including the locations in the Isometric
drawings. Instruments and piping items have their own specific and unique labels which indicate
tag numbers for easy identification. Proper handover for installation to be in place. Only pipe
spools and fittings required for immediate installation should be released from the storage area.
Traceability for conform to Material Handling and Traceability MoS, please refer: TZ-TAN-94-
BBJ1-200389
For traceability and stock control, the following data is to be maintained for all material;
 Item No.
 Quantity
 Receiving date
 Condition of the item during receipt
 Issuance date and sign-off from store
 Serial/Tag No.
 Location installed
 Any special identification Eg. Heat No.
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Rev. Date:
3.3 Dimensional Check:

All GRE pipe spools' lengths should be measured according to the given associated AFC
Isometric, before getting placed in its exact location. Before the GRE pipe spool has been placed,
the dimension check is to be performed by the Surveyor as well as Manual measurement to be
done by GRE Pipe fitters.
3.4 Preparations:
Before commencing the fit-up process of the GRE pipe, the safety team will conduct a thorough
verification of the temporary platforms e.g. Scaffolding and the general work environment. Once
the safety team has confirmed that the temporary platform meets all applicable safety standards,
they will grant permission to proceed with the permit to work that will be obtained from the
concerned department. Permit to Work application procedure shall be adhered to.
The mechanical team shall mobilize equipment, tools, and correctly identified pipe for fit-up
according to ASME B31.3 2018 Section 328.4. The joint shall be cleaned and free from paint,
oil, rust, scale, and other materials. Where the spool pieces to be fitted require the use of cranes
for hoisting, such plant equipment is to be provided.
3.5 Cutting & Bevelling for Field Joints
For field pipe bonding where extra pipe length (+150mm) is kept to ensure the proper alignment
of bonds, the extra length as per site conditions will be trimmed out. The process will involve a
survey to measure the extra pipe section, and temporary marking of the section to be cut by
grinder. The site engineer, WCL QC, client, and consultant teams will be invited for inspection
to ascertain the requirement for trimming as well as the marked length to be trimmed. If/when all
parties are in agreement and approval is given, the GRE pipe fitter will proceed to permanently
mark the exact cutting point with a centre punch.
The grinder will then set up the motorized bevelling machine on the GRE pipe section to be
trimmed ensuring the cutting is well aligned with the pipe cut marking. During the cutting
process, a fire blanket shall be maintained on the floor to contain the spatters from the cutting
process.
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3.6 Fit – Up
Once the GRE pipe bevel has been cleaned to ensure it is free from paint, oil, rust, scale, and any
other contaminant, the faces of the two pipes are pushed together and GRE pipe size will be
adjusted so as to meet the required size so as can be fitted well and injected to the next pipe size,
shaver will be used to prepare a spigot end for an adhesive bonded joint on a pipe
Figure 3: Shaving of a spigot end
The GRE pipe will be shaved to allow fitting of the pipes considering dimensions of the pipes to
be connected, shaver will be used to prepare a spigot end for an adhesive bonded joint on a pipe
and then after adhesive bond will be made, and spigot prepared by shaver will be made, GRE pipe
will be joined to end adhesive bond joint and move to the next step of Lamination, after inspection
of QA/QC engineer and confirmation from QA/QC engineer, the laminated adhesive bond joint
will join plain-ended pipe. Then we will apply heat, using heating blanket, heating blanket will be
used to cure adhesive bond and lamination joint.
3.7 Lamination of the adhesive bonded Joint

The process will be laminating of the adhesive joint pipes, the laminated joint will join plain-
ended pipe. After preparation of the pipe surfaces, a specific thickness of resin impregnated glass
reinforcement will be wrapped over a certain length around the pipes to be joined; the thickness
and the length of the laminate will be related to diameter and pressure. Joint will requires
following tools/materials: Gloves, dust mask, safety glasses, Measuring tape, marker, pipe fitters
wrap around, angle cutter, hand saw or jig saw, grinding tools, flexible support disc, rubber
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scraper, scissors, brushes, resin, hardener and glass reinforcement, Air gun, gas burner or field
oven, insulation blanket, digital temperature gauge, cleaning brush, non-fluffy cleaning rags and
cleaning fluids.
Figure 4: Lamination of the adhesive bonded Joint
3.8 Application of heat blanket

In applying of heat, heating blanket will be used to cure adhesive bond and lamination joint.
Blankets that made from a coiled resistance wire, which is sandwiched between two layers of
silicon rubber will used to control the temperature, the blanket will be furnished with a thermostat,
to store the heat of the blanket properly in order to keep this tool in an optimal condition, heating
blankets will never be folded, and will be stored flat or rolled.
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Figure 5: Application of heating blanket
3.9 GRE flange joint

GRE Flange will join GRE pipe, GRE flanges will be aligned with the counter flange to avoid
high stresses, GRE flange joints will be tightened with limited torques, to ensure leak-free flange
joints.
Figure 6 : GRE flange joint
Tools and materials that will be in use in bonding of GRE pipes are ring spanner, torque wrench,
gasket, bolts, nuts and washer, whereby fitters will be assigned to fit and tighting of all GRE
flange joints. The GRE joints of the pipeline will be able to withstand a pressure of 70bar. All
open ends shall be closed with stoppers before testing begins and water shall be filled from the
lowest point during hydro test. No entrapped air shall remain in the pipeline while testing. Rapped
air shall remain in the pipeline while testing. A pressure of 70bar shall be maintained for one hour
to allow the initial absorption of water. After that, the test pressure shall be maintained for 15 min
and the water added shall be measured, if water consumption in 15 min does not exceed 0.1l/m2
of wetted inner pipe surface and if there is no visible leakage through joints, the pipeline shall be
treated as passed.
3.10 Pipe supports installation

Installation of GRE pipe supports to be as per AFC drawings. Before fixing supports, location,
and coordinates are to be counterchecked by the site engineer. Supports are to be installed in a
way such that there’s no tension on the installed pipe support. Packing with shim plates to be
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added to locations that have a gap greater than 2mm between the top of the structural and bottom
of pipe support. Hanger Support rods are to be adjusted as per site conditions.
3.11 Pipe cleaning and preservation

Installed GRE pipes to be flushed internally using compressed air to remove any foreign debris
before handing over. To maintain pipe cleanliness, preservation caps are to be placed both on the
pipe end and flange connections.
The valve removed for Pre-Commissioning purposes is to be covered/wrapped with waterproof

tarpaulins/canvases to prevent water damage. Valve face cover caps shall be used to protect the
valve faces from mechanical damage.
3.12 Hydro test

Hydro test shall be done after full pipe adhesive bonded/connected, laminated and heated has been
completed in the various test packs. It shall be organised into test packages with similar test
pressure as per the provided line list with line specifications. Hydro test shall be as per MoS ETJ-
BB-QA-MS-GEN-ME-0009.
Hydro test spools shall be fabricated from material with similar specs to the main line. The spools
shall be used for filling, pressurising and draining of the pipes. Provision for instruments
attachment shall also be provided in the spools. Valves and instruments shall not be exposed to
pressure test.
Document Number:
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Rev. Date:
Figure 7: Sample picture of hydro test
3.13 Valves and Equipment installation

Valves and instruments shall not be used during pipe fit-up apart from those bonded to the pipes.
Dummy spools shall be fabricated to replace the valves during fit-up to maintain the gaps. The
spools length shall include the thickness of the gasket to be used. This shall serve to ensure there’s
no strain on the piping when the final box up/reinstatement is done.
Valves flanged ends shall be protected at all times using snug-fitting end caps.
Gaskets shall not be re-used unless inspected and found to be in good condition.
Threaded connections on instruments shall be protected from damage and dirt ingress using
threaded plugs of the same material and finger tightened.
Bolted connections shall be tightened using manual torque wrenches but bolt sizes above 1.25”
shall be tightened using hydraulic torque wrenches. Bolt torque shall be applied in three stages
using the cross-pattern tightening sequence defined in Table 4 of ASME PCC1-2000.
3.14 HANDLING AND STORAGE

3.15 Materials control
End protection of piping components will remain in place during handling. Pipes and fittings will
be handled with care and protected from impact. Throwing, dropping, bumping or hitting the pipes and
the fittings will not be allowed. Pipes will not be dragged or pushed over sharp objects. Pipe will
not rest on the floor of the container where nails, studs or other sharp objects might damage it.
Pipes will be placed and laid on wooden sleepers. The pipe will be securely fastened directly over the
timbers with tie downs such as nylon straps or ropes. Steel wire ropes or others sharp material will not
be used which might cause damage. No other materials will be loaded on the top of the pipes. Pipe
drop or walk or stand on it will not be allowed.
3.16 Inspection
Document Number:
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3.17 Handling
For pipe and components supplied with machined parts, the Manufacturer will apply external and
internal closed end machined parts protectors to protect the ends and all exposed machined parts
of the pipe, coupling and fittings from damage under normal handling and transportation. For
machined parts connections, the end protectors shall also protect the end face and the outer surface
of the bell-end to prevent chipping and impact damage. Machined parts protectors will exclude
foreign matter such as dirt from the ends. Protector material will be plastic and contain
no compounds capable of damaging the machined parts or making the protectors adhere to the
machined parts.
3.18 Storage of GRE Pipe

As GRE pipe, when storing, we will pay attention to not being squeezed by heavy objects, even
for hard pipes, secondly, when placing, we shall fix it with wooden stakes at both ends of the stack
to prevent them from moving around, and finally we shall protect GRE pipe from sun if necessary.
All pipes, fittings or components used in the pipeline system shall be inspected for damages, prior
to the actual bonding activity. Rejected items shall be separated and quarantined from undamaged
materials to avoid unintentional use.
Adhesive kits shall be inspected prior to use. We shall not use adhesive kits or containers showing
evidence of damage or leakage. The adhesive shall be used before the expiry date, which is shown
on the adhesive kit. We shall make sure that storage of adhesive kits complies with the storage
requirements.
We shall ensure all necessary tools and materials are available, by taking notice of the safety
precautions stated in this document and those in the referenced instructions.
Pipes with bell-ends will be stored with the bell-ends in alternate directions. To avoid contact with
and damage to the ends, mating surfaces or machined parts. Wooden or plastic spacers will be used
and will be of sufficient size and strength to prevent contact between pipes. Spacers will be
located clear of the bell-ends.
Document Number:
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Rev. Date:
Figure 7: Sample picture showing Storage of GRE pipe
4 HEALTH, SAFETY AND ENVIRONMENT

4.1 Health and Safety
Before commencement of any task JSA & Risk assessment (Document Reference Job Hazard &
Risk Assessment_ BBN TZ_ Project TZ-TAN-94-BBJ1-200393) must be approved by the Safety
department. The same documents are to be shared with the project execution and before
proceeding with the approved task a meeting will be organized between the site teams in the
presence of the PM so that the ineptness of the JSA goes up to the bottom-line staff and workers
executing the work.
Tools and equipment are then inspected and inspection checklists are populated before starting the
work. All faulty equipment and tools are kept aside for repair and maintenance. Those beyond
repair are condemned. Only the tools and equipment with correct colour coding and in good work
order are allowed for use on-site. All hand tools to be used on platforms overhanging the sea
should be secured well with a rope to prevent them from dropping into the sea. The permit-to-
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work system in place is adhered to at all times. Before the commencement of any no routine
works, a permit to work is sought from the Safety department. The PTW is only applied and filled
out by the designated staff and approved by the safety department. If the permit is not issued or
there is a change in the conditions of the working area/ introduction of new hazards, the same
should be included in the permit of a new permit raised. All equipment and tools inspection
checklists are attached to the permit to ensure compliance. All other safety requirements from the
clients not limited to the safe use of PPE, JSA, and PTW to be adhered to
4.2 Tasks Daily Briefings

Toolbox talk will be conducted for daily task briefings before site work starts. The discussion will
be conducted for various hindrances and obstructions that occurred during the site work for the
earlier days. In this discussion, it will be discussed for any betterment of this process by which
productivity can be increased keeping safety and quality in top priority.
5 EQUIPMENT AND MATERIAL
5.1 Equipment
5.1.1 Construction Equipment
a LPG Cylinder
b Welding Machine with Welding Cables & Holder
c TIG HF Machine with Argon Torch
d Torque Wrenches
e Hydraulic Jack 50 Ton cap
h Grinding Machine AG 9
i Grinding Machine AG 4
j Tri Pod 3 Ton
k Welding generator
TOOLS
k Lifting Belt up to 1 Ton
f Chain Block 5 Ton Cap
g Chain Block 3 Ton cap
a Pipe Clamps
a Pipe fit-up Jig
b Wedges
c Bull pin
d Jointing Cleat
e Tacking Bridge
f Claw Bar
g Spirit Level
h Measuring Tape
i Air blocking Shield (canvas)
6 PERSONNEL
6.1 Personnel Protective Equipment (PPE)
a Coverall
b Safety Shoe
c Helmet
d Mask
e Ear Plug
f Safety Goggles
g Hand Gloves
h Safety Harness & lifelines
i Welding / Grinding apron
j Ankle guard
k Life Jacket (by BBN)
6.2 MAN POWER

6.2.1 Supervision Staff
a Project Manager
b Project Engineer
6.2.2 Execution Staff

a HSE Officer
b Quality Inspector
c Supervisor
6.2.3 Man power

a Welder (SMAW)
b Welder (TIG)
c Fitter
d Grinder
e Rigger & Helper
6.3 DECRIPTION OF THE WORK.
GRE Pipe installation works will include erection and positioning of trestles containing 14’’
diameter GRE pipe. This erection will be done by BBN TZA. WCL scope will be the stringing of
the 14” GRE pipe to be used as the fire fighting facility for the EACOP project.
Pipes in subsequent trestles will be connected using the method/procedure described in section 3
(Sequence of work) described above. Additionally, expansion loops will also be fitted and bonded
at given intervals per the Approved Fabrication Drawings (Isometrics and PI&Ds)
The GRE pipeline will then be supported using prefabricated fixed and guided supports. WCL will
fit and weld these supports per the installation drawings and guiding procedure TZ-TAN-94-
BBJ1-200249_00_IFR_20230921.
The piping installation for the various sections of the pipeline shall proceed as described below
6.4 Pipe Installation in the Shallow Section
This procedure describes the procedure to be followed for the installation/assembly of the 14-
inch GRE pipe in the shallow section only. This includes installation of the straight section of the
pipe inside the trestle, expansion loops as well as pipe supports.
6.4.1 Straight pipes installation in the shallow section

The straight pipe sections shall be in 12m lengths and placed inside the trestles during installation.
However, the 12m pipe sections will not be in their correct project centre lines as they will be
offset during transportation for weight distribution. The pipe trestle shall be erected with the GRE
pipe offset 750mm in the North-South and 800mm in the east-west direction.
Therefore, after the erection of the trestles, the GRE pipe shall be moved to the correct pipeline
centreline using the crane.
Figure 4- Pipe layout inside trestle during transportation
To achieve this pipe position adjustment using crane, two grating platforms on top of the walkway
will be removed. This will allow lifting tackles to pass through the trestle and attach to the
chocker belt around the pipe.
6.5 Expansion Loop in shallow section

To achieve Expansion loop installation at shallow section, hanging platform will be erected, for
installation of spool piece 1, 2 and 3 as shown in figure 4 below. The steps that will be followed
are: first step, two elbow flanges of 90 degree will be connected to GRE pipe of 2933.2mm with
the method of shaving and bonding of the pipe at SPOOL1 and SPOOL2 respectively as explained
3.6
Then, two flanges elbow of 90 degree will be connected to GRE pipe of 2933.2mm with the
method of shaving and bonding of the pipe at SPOOL 1 of pipe. The connecting pipe between
SPOOL 1 of the pipe and SPOOL 2 of the pipe will be of 1933.6mm that will be done by the
support of erected scaffold. SPOOL1, SPOOL 2 and SPOOL3 will be held with crane during
installation of the flange and bonding.
Figure 4: Expansion loop installation.
Spool 1 shall be lifted and erected to position using the mobile crane. The spool piece will be
prefabricated and the support attached to the pipe before erection. During erection, the spool piece
will be secured using temporary wooden support to assist with the alignment of field bond.
Spool 2 shall be lifted and erected to a position using the mobile crane and scaffold erected will
support in fit up activities and bonding of GRE pipe.
Spool 3 shall be lifted and erected to a position using the mobile crane and scaffold will support in
fit up activities and bonding of GRE pipe.
6.6 Pipe Installation in the Deep Section

Along the GRE pipe interval, expansion loops will be installed in the deep section, the loops will
be prefabricated into three spool pieces to be assembled on-site. Scaffolding shall be erected
around the section where the expansion loop is to be installed. The working platform shall be
maintained at least 600mm from the bottom of the pipe for easy joint access.
Figure 5: Expansion loop at Deep section
For the installation of expansion loop at deep section, the following procedures/steps will be
implemented for complete execution; a hanging scaffolding platform shall be erected to form a
working platform for the mechanical team. The platform shall then be inspected to ensure it is safe
for use and tagged. The rigging team shall then with the help of the mechanical team identify the
spool piece and ready it for erection.
As shown in the figure above, SPOOL 1 will be connected with elbow, the spool shall consist of
an elbow and pipe bonded together, crane will then lift and swing the spool to position where a
standby mechanical team shall be waiting to guide and position the pipe.When swinging the spool
to position, care shall be taken to ensure no team is under the suspended spool at any time. Crane
will be holding until end of the installation.
SPOOL 2 shall be lifted and erected to a position using the mobile crane and scaffold erected will
support in fit up activities and bonding of GRE pipe, flange elbow of SPOOL 1 will be fitted and
bonded to SPOOL 2.
SPOOL 3 shall be lifted and erected to a position using the mobile crane and scaffold will support
in fit up activities and bonding of GRE pipe, Spool 3 will be prefabricated and bonded to an elbow
flange. A pipe. +150mm length is added to the pipe length given in the drawing to allow for any
adjustment during field installation. There fore, a Survey shall be done to determine the spool
length required as per site conditions. The extra spool length is then cut using a grinder.

Method Statement For GRE Piping Tanga

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Document Number:

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

Method Statement - Field GRE Piping installation

Rajib Banerjii Mehmet Yilmaz C. Eris / F.

Rev. Step Date Revision Description Issued by Reviewed by Approved by

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

HOLD No. Description of Holds

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

COMMENT RESPONSE SHEET

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

INPUTS / REFERENCE DOCUMENTS

Document Number Title Status

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

3.14 HANDLING AND STORAGE...............................................................................................18

4 HEALTH, SAFETY AND ENVIRONMENT...................................................................

5 EQUIPMENT AND MATERIAL....................................................................................

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

1.2 Document Purpose

1.3 Acronyms, Abbreviations and Definitions

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

1.4 Requirements & Standards

2.1 Work Location

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

2.2 Scope of Work

Figure 2: Flow Chart for GRE pipe installation.

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

4) GRE Pipe Fit up.

2.3 Roles and Responsibilities

2.5 b) HSE Officer:

2.6 c) Piping Engineer

2.7 d) QA/QC Inspector

2.8 e) Piping Supervisor

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

2.9 Planned Start Date and Duration

3.1 Approved Construction drawings

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

3.3 Dimensional Check:

3.5 Cutting & Bevelling for Field Joints

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

Figure 3: Shaving of a spigot end

3.7 Lamination of the adhesive bonded Joint

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

Figure 4: Lamination of the adhesive bonded Joint

3.8 Application of heat blanket

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

Figure 5: Application of heating blanket

3.9 GRE flange joint

Figure 6 : GRE flange joint

3.10 Pipe supports installation

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

3.11 Pipe cleaning and preservation

The valve removed for Pre-Commissioning purposes is to be covered/wrapped with waterproof

3.12 Hydro test

CONTRACTOR Doc. N°: ETJ-WC-DE-MS-GEN-ME-0001 System / Subsystem: NA Equipment Type: NA

Figure 7: Sample picture of hydro test

3.13 Valves and Equipment installation